Manure Production Capacity in Kg (per dairy cow)

               Below table and the graph specifies manure production capacity of a cow related with its milk production:

             

Manure Capacity per Cow - kg/day	Milk Production per cow - kg/day
50	15
60	25
70	35
75	45

         

Dairy Farm Feasibility Project for 100 Units Heifers

Generally, when a dairy farm started with 100 heifers according to the normal conditions following the end of the 2nd year the herd circulation is expected to begin. The most important two factors here milk and cemen efectiveness.

CLOSED AND OPEN AREAS:

Barns

According to the calculation that from each preganant heifer one new calf has been obtained, the farm will own 90 calfs (10% wastage ratio). Expecting the 50% is male and the rest is female, totally 90 units should be located in a different barn.

Feeding Storage and other Areas

Area	m2
Feeding Storage	291
Raw Feed Store	233
Silage	818
Materials	48
Maternity (2 units)	20
Infirmary	20
Milking Parlour	83
Manure Pit	347
Walking Alley	1897
Total Alleys	3055
Garden	162
Farm House	81
Management	49
TOTAL	7.104

                                          
STUDS:
    

Studs should receive all necessary health maintenance with shiny hairs, vaccinated.

100 x 2500 Euro

                          

MACHINERY AND EQUIPMENT:

Machinery	€
Automated Milking Parlour and Machinery (5 x 2)	30.000-35.000
Feeding Grinding Machine	550
Feeding Mixer (6 m3) – 1 Unit	11.000
Water Trough (4 Units)	1.200
Automatic Cow Brush (4 Units)	2.200
Cubicles (for 100 herds)	4.500
Calf House (20 Units)	3.200
Bedding Material (for 100 herds)	5.000
Milk Cooling Tanks (5 ton)	5.400
Manure Scraper (4 units)	14.000
Tractor	15.000
Manure Separator	11.000
Rubber Mat (for 100 herds)	5000
Manure Pump and Mixer	4000
TOTAL	117.050

                             
FEEDING COSTS: 

Prepared as 600 Kg, 3,2% fat, 3,8% protein, 5% lactose 30 lt. milk per milch cow

AMOUNT  ( Kg)	FEED	€
20	Corn Silage	0,71
4	Alfalfa	0,32
1	Razmol	0,12
2	Corn Flakes	0,29
1	Wheat	0,11
2	Soya Pulp	0,56
0,1	Vitamin Premix	0,22
0,1	Dicalciumphosphate	0,26
30,2	TOTAL	2,59

       

        **In order to obtaine high milking capacity by-pass fat and protein can also be used.  On the other hand these may inrease the feedign costs. Above mentioned table will be enough for 25-30 lt capacity.

MILKING COST AND INCOME: 

. Feeding cost of 1 lt milk              :  2,59 € / 30 lt milk = 0.086 €  
. 1 Liter raw milk selling price (% 3,5 fat) : 0.30 € (A quality can be sold at  0,41 €)
. Milk income per cow                  :30 lt raw milk X 0.30 € = 9 €
. Net Milk income per unit:
9 € (income) – 2,59 €  (feeding cost) = 6,41 € (Income per livestock)

Mostly used dairy breed types: 

Ayrshire

Brown Swiss

Busa

Canadienne

Dairy Shorthorn

Dutch Belted

Estonian Red

Fleckvieh

Friesian

Girolando

Guernsey

Holstein

Illawarra

Irish Moiled

Jersey

Kerry

Lineback

Meuse Rhine Issel

Milking Devon

Montbéliarde

Normande

Norwegian Red

Randall

Sahiwal

Agriculture and Dairy Farming Exhibitions List - 2014

1-) INAGRITECH 2014 ( 19-22 March )  - Indonesia
2-) AGROEXPO EURASIA 2014 (18-21 September) - Turkey
3-) FSSHOW 2014 - (6-8 March) - China
4-) MODERNAGRO 2014 (18-20 June) - China
5-) AGMET 2014 (29-31 March) - China
6-) ANIMALIA ISTANBUL 2014 (20-23 February) - Turkey
7-) AGROTECH (07-09 March) - Poland
8-) SEMINAT (07-09 March) - Italy
9-) AGROTECHNOLOGIES - (18-20 March) - Russia
10-) EUROTIER 2014 (11-14 November) - Germany
11-) ILDEX - VIETNAM - (19-21 March) - Ho Chi Minh City, Vietnam

1    12-) Fieldays  11-14 June 2014 , New Zealand

2    13- )     National Farm Machinery Show, 12-15 February, Kentucky, USA

3    14- )    World AG Expo, 11-13 February, Tulare, CA, USA

4    15- )     Lamma, Farm Machinery Show, 22-23 January, Peterborough, UK

6    16- )     Agrama, 27 November – 01 December, Bern, Switzerland

7    17- )     EIMA, 12-16 November – Bologna , Italy

Click here to see the full list of exhibitions in 2014 

Dairy Farm Sample Photos with Manure Handling Equipment

            Informational photos from a dairy farm including the equipment like manure separator with its steel platform, submersible manure pump and mixer with raw manure pit and chain manure scraper in the barn:


Raw manure pit:
               

Barn with cubicles:

Chain Manure Scraper with Drive Unit:

Manure Separator on its steel platform:
                           

Renewable Energy Source for Dairy Farms : Biogas

           Biogas in dairy farms simply obtained by the anaerobic digestion with the manure collected in the farms, it converts the cow manure into methane biogas. With the help of the digesters and the mixers in these and also generators basically the manure is used to obtain electricity and heating for these farms. Therefore the farm by itself can be able to use this electricty and heating for its own needs. In Germany today many dairy farms have such installations. Not only it has benefits in economical points (producing electricty and heating) but also biogas systems may reduce global warming. (It reduces nitrogen dioxide and methane oscillation both of which heat the atmosphere).

     

   

What is Centrifilter? Filter Separator Integrated with Manure Separator

        Filter Separator is designed to separate solid and liquid phases of fiber-rich waste materials. The waste should be free of sand, as well as other foreign objects such as metal, glass, wood, etc. that have the potential of damaging the internal parts of the separator.

          Slurry can be fed into the Centrifilter either by a pump or gravimetrically through a hopper at the inlet. The helically formed conveyor inside the separator moves the slurry forward from the inlet section towards the solids discharge outlet. During this travel of the slurry, the polygonal screen around the conveyor continuously dewaters the liquid fraction of the slurry. Meanwhile the dewatered solids translated to the discharge area where they discharged gravimetrically.

            Operational efficiency of the machine (throughput and dryness of solids) is greatly affected by the slurry consistency. Therefore performance results may vary depending on what kind of slurry is being dewatered. Following principles should be kept in mind when optimizing performance.

·                    Separation efficiency is typically increased when a larger screen slot-size is used. This in turn will result in more solid particles to escape into the separated liquid phase.

·              Smaller screen slot-size typically results in less solids percentage in the separated liquid phase. However throughput will be lower with smaller screen slot-sizes.Homogenous feed composition dramatically increases the operation and separation effectiveness. However, adjusting the mixing duration and interval considering the manure pool volume is crucial to prevent changing manure composition negatively for the separation.

           When feeding and bypass line lengths exceed 10m, pipe locations should be reassessed. Locating the pipes underground may result in capacity loss, clogging etc. Bypass and feeding lines should be slopped to allow the manure flow into the machine. Centrifilter discharge line is 4” in diameter. The line diameter between liquid discharge and liquid pool must be at least 4”. Similarly, a slopped fashion of pipe location is recommended to prevent clogging in discharge lines.

           Isolating the inlet and discharge lines may help avoid freezing.

Benefits of Using a Manure Separator in Dairy Farm

            Manure separators in the dairy farm first of all recycles the excess manure accumulated in the barns. In order to collect all raw manure in the pit or throw it away and cause pollution in environment, farms can separate the solid and liquid phases of their raw manure and utilize the outputs in their own farms or can sell in the market. Therefore separation of manure enables the dairy farms not to waste their manure supply and also enables them to make profit from their own material.

         A manure separator is mostly coupled with a submerisble pump and mixer for raw manure pit. Investment costs are low comparing to its benefits. Today many countries in the world apply regulations on the protection of envrionment, and the manure separator by itself apart from its profits is a milestone to protect the environment.

Submersible Manure Agitator Explained

     Submersible Agitators are used in raw manure pits in dairy farm to mix the manure and to provide it to stay liquid. Recommended mixing time in the pit is at least 4 times a day. With the help of the agitators submersible pump will be able to pump the raw manure into the separator effciently. The power of the pump is calculated according to the size of the pit. A standard pit diameter is 10 mt.

    Submersible Agitators have one unit three-phase submersible motor with the electric connection cable and also oil reservoir, planet shaft and propeller. There is one unit terminstans to determine over heating in the electric motor. This is connected to the protection relay called “STR” in the panel.

     In the body of the engine and oil reservoir there is one unit liquid leakage probe. This probe is also conencted to the STR which protects the agitator against liquid leakage and and over heating (max .110 oC). Inside the panel one unit relay for motor protection also defends the agitator against high current values. In addition to all these protection there is also one unit FKR phase protection relay which prevents the damages to harm the agitator and the equipment in the panel that may occur from instability in the phases. The electric control box having all these protection can be supplied as an equipment of the agitator.

Bedding Composter for Dairy Farms - Compost Drum Explained - Bedding Material for Cattle

           Bedding Composter is a semi-closed system known as “in-vessel composting” in compost literature is a aerobic compostioning technology. The system basically prepares the ideal conditions for accelarating the activities of the bacteria in the organical waste. The moisture ratio temperature and oxygen flow in the drum is under controlled by the system automatically and computurized way.The drum is turning on low speed and while turning the solid on the other way provides the movement towards the outside. The solid wastes which stays inside the drum on average of 24-72 hours as a result of the activation of aerobic bacteria reach the temperature of 60+oC without any energy consolidation.

         For the continuation of bacteria activation and continuity clean air is given into the drum with computer control and the exhaust gases are taken to the outside. Pathojens inside the waste which stays 24 hours this temperature are eliminated and the fermentation process have mostly been completed. It includes a specially produced polimeric and cylindirical drum for the compostioning process.

         The drum which takens the moisturized material inside turns oftenly on low speed and therefore provides the regular mixture of the material its contact with the oxygen and easy idscharge of the fermentation gases. Meanwhile the system regularly provides oxygen flow inside the drum. The organic material inside the drum starts to aerobic fermentation in a short time and the temperature of the drum reaches 60+C. This temperature completely occurs from the heat which comes out of activities of the aerobic bacteria there is no any energy consolidation from outside. The material which is kept 24-72 hours. on these temperatures cleans from the harmful bugs and bacterias and completes the mineralization period mostly to obtain compost. Bedding Composter has computer control. The system monitors and controls the important parameters for compostioning like on which speed and amount the material will be taken into the drum, the turning speed of the drum, air flow that should be provided inside the drum, the temperature inside the drum and also arranges these parameters as related with each other.

           

         Therefore it is the system which regularly produces compost without the assistance of any technician. Bedding Composter is a continued compost production system. After the determination of the stay period of the material inside the drum the system regularly supports material to the drum and the material which completes the period is discharged from the drum. The main function of its system is to provide the suitable environment for the fast accumulation of aerobic bacteria and to decompose the organical material. Following the decomposition process the materal will become a stabile compost, the organical material in the manure will become mineral form and therefore it will be assimilated by the plants easily. This is the main characteristics of the compost that differs it from animal excrement. The material does not reveal any waste gas, it is completely purified from smell and it is not different from natural soil as image and structure. The material came out of the Bedding Composter is directed to Curing Area. After the material kept in the drum for 24-72 hours even the fermentation is mostly completed, low level aerobic reactions continue inside and it did not become a stabile compost. For the Curing the compost should rest and become mature. At this stage the compost is made as triangle section windrows and these are periodically mixed for 7-10 days (once in a day). With the help of this the windrows has the oxygen and the rection gasses are exhausted. The turning is being done with Compost Turner which is pulled by a tractor. While turning the windrows at the same time fragments the lumpy parts and also moisturize with its water tank spray mechnanism. Especially during summer time moisture support is necessary for the windrows.


         For the Curing stage of the Project 1.200m2 area is necessary.(i.e 40mx30m) Compost turner which is operated with a tractor, mixes the material with fixed speed in homogenic way. There is no need to tidy the windrows after the first creation. With 900m3/h turning capacity, while turning the material without scattering at the same time harmonizes the windrows. With the help of the 800 lt water tank spray system which is integrated to the machine, water or the other organical liquids for moisture and quality increase can be given to the windrow with the desired frequency and ratio. The drum width of the machine which weights 6500 kgs is 3.2 mts and the tunnel height is 1.8 m. For closing the turning effect area to the floor all the machine hydraulically can be moved 12 upwards-downwards. All hydraulic functions is directed with control panel by the operator of the tractor. During this stage 1 day turning period will be enough. The compost acquired at the end of this period has a structure and quality to be marketed. The compost which completed its Curing period and become stabile is ready for packaging. Compost is directed to packaging line from here and than transfered to product stock area.

Dairy Farm Machine - Solid Manure Spreader

                 Another application which can be used in the dairy farm for the utilization of the waste manure is solid manure spreader. While using the slurry tanker for the liquid manure the farmer can also run a manure spreader for the spreaidng of solid manure.

               


   

Dairy Farm Machine - Slurry Tanker in Dairy Farms for Distribution of Liquid Manure

          Slurry Tankers provide great solution for the dairy farms to handle the liquid manure. It is specially designed for both implementation and transportation of solid fraction and liquid fraction which comes from the separator. The Slurry Tanker with its powerful compressor is loaded and unloaded in 1 to 3 minutes. Liquid manure is spreaded homogeneously to 16-20m sized semicircle area at the back of tanker. Off-the-road tires' maneuverability provides convenient ride on every type of land. The farm is able to transport the waste in a safe and practical way while  increasing the productivity of the land significantly.

           It is recommended to run slurry tanker after the manure separator separates the liquid phase of the raw manure collected from the barn. Each country's regulation can be different from each other regarding the capacity of the tanker, however the usual range is between 5 tons to 20 tons.

Click here to get more information on semi-trailers

                           

Benefits of Using a Cow Brush in Dairy Farms

                Designed to provide relief and relaxation to cows by cleaning and massaging their skin. Dirt and dust that accumulate on cow’s skin cause discomfort to the animal and can harbor harmful parasites if not cleaned off periodically. Cow Brush provides a self-cleaning set up for the cows, eliminating the need for any labor or operator attendance for this purpose.

             The brush is activated by means of a movement sensor. It starts rotating as soon as the cow touches the brush. Likewise, brushing action is programmed to stop 30 seconds after the animal moves away from under the brush. The brush is designed to swing in two separate directions, and its position is easily manipulated by the animal. The cow can easily brush its entire upper body with ease, from head to tail.

            The rotation of the brush allows it to travel along and across the upper body of the cow. If the brush encounters a certain level of resistance from the brushing surface, it automatically stops and starts turning in the opposite direction to prevent any harm to the animal.

                 

              Cow Brush accomplishes two important objectives at the same time. It cleans the skin of your cattle from dirt and dust, and it massages the animal. Advantages of keeping the skin of the animal clean are obvious.Cleanliness is the first step towards a healthier body. And skin that is free of dirt breaths better and has better chances of keeping the parasites away. With its brushing action, it can actually get rid of existing parasites as well. Massaging action also helps to maintain healthier animals. With its gentle yet stimulating bristles, it improves the blood circulation in the small veins close to the skin. It also relaxes the muscles in the upper portion of the body. As a result, the cow is helped to stay in a relaxed state at all times, which is scientifically known to improve milk output in dairy farms.

How to run a Compost Turner

                If the compost turner in your dairy farm PTO run model first you should connect the shaft to the PTO of the tractor. Be sure all electric and hydraulc connections are correct. Bring the system down with the help of the control panel, take out the drum connection pims and run the warning lamp on the top. When you approach to the windrows take down the drum slowly with help of the hydraulic pistons, run the power takeoff (PTO) and arrange the rpm lower than 1000. Enter the windrow with a low speed, keep in mind that the stones in the windrow can harm the people around so be sure no one is near the machine while working.  After the windrow process cut the PTO connection and hold the drum to carrying position with the help of the pistons. With this function it aerates the windrow for oxygen supply, breaks down the solşd particules inside, regulates the temperature and maintains the humidity level. These features faciliates the chemical reactions necessary for high quality compost.

           Windrows should be arranged as 3 mt. wide and 1.6 mt. height. The aisles between each windrow should be 2.5 mt. in order to allow a standard tractor to enter.

       

Dairy Farm : Manure Scraper in Details

                Manure Scraper as per below photo consists of scraping car, a driving unit (gearbox), electric control panel and chain/rope as pulling system. The chain or rope is installed in a steel profile called as NPU65 or NPU80. It has 5 mt per minute speed which can be arranged automatically. Generally  5 times a day scrapping is recommended by manufacturers. Manure scrapers has their own sensors in order not to harm the livestock. With the help of these sensors they stop instantly and wait until the cows passes to the other side and empties the alley.

              In order to clean the barn and collect the manure manually it easily does its job and completely clears the barn and collect the accumulated manure into the raw manure pit which has been built at the end of the barn. In below photo manure scraper with its collection pit at the end can be seen:


                                       

you may watch the manure scraper video here: https://www.youtube.com/watch?v=ZyoZByu_r5U

Composting Technologies and In Vessel Composting in Farms

              There are several manure handling and composting equipment. Composting nowadays become very popular especially in the USA and the EU. In Germany many dairy farms have their own biogas systems to produce their own electricty and heating. 

            Slurry can be fed into the Separator either by a pump or gravimetrically through a hopper at the inlet. The auger inside the separator moves the slurry forward from the inlet section towards the solids discharge outlet. During this travel of the slurry, the cylindrical screen around the auger continously dewaters the liquid fraction of the slurry and channels it out through the liquid discharge outlet. Meanwhile the dewatered solids form into a firm plug as they get closer to the discharge area. At the solids discharge outlet, there are two hinged doors that apply constant pressure to the solid plug by means of counterweights attached to the arms that regulate the angle of these doors. As the auger furthers the solid plug forward, the plug overcomes the backpressure applied by the discharge doors and exits the machine from the discharge outlet. 

          The manure which is homogenized and collected in the raw manure pit is pumped to the separator. Compost drum system is semi-closed system aerobic composting technology known as “in-vessel composting” in world compost literature. Basically, the system provides ideal conditions for fastening the facilities of the bacteria in the organic waste. Depending on the process duration in the drum the end product can be used in two different ways. They are bedding for the cattle or as compost fertilizer. In different climate conditions the output structure and results may vary. The results can also cahne according to the feeding style of the dairy farm. 

          The material that is separated and spilled in the drum is agitated consistently and at the same time the oxygen which is necessary for the aerobic fermentation provided with PLC controlled fan for ventilation. The temparatıre inside the drum reaches 60+^OC .

              

                     

 

Dairy Farms - Manure Separator

           Today many countries in the world use manure handling equipment in dairy and pig farms. In the USA, Netherlands, Germany, France and also in South East Asia like Vietnam, Malaysia and Thailand. Manure separation technolgy is simply dewatering the manure obtained in dairy farm barns into solid and liquid phases.

          For this, the manure scraper firstly is installed in the barn in order to collect the manure accumulated. Manure scraper collects the manure into a concrete pit at the end of the barn. According to the design of the dairy farm the manure scraper can chain or rope type. Following the manure collected in the raw manure pit it is transfered into the manure separator with the help of a submersible manure pump.

         Manure separator dewaters the raw manure entered throught the pump and outputs solid phase on a romork of a tractor and liquid phase to the liquid manure pit. Both solid and liquid manure obtained from the manure separator can be sold to market or also can be used in the dairy farm itself. Therefore a farm can recycle the raw manure from cows and use it fo its own benefits or can earn money by selling the solid manure to fertilizers.

             

         By the use of compost turner, additionally, the solid phase can be ventilated and a compost can be obtained in 1-2 weeks.

          Alternatively, a bedding composter can also be integrated to this system and the output from the bedding composter can be used as bedding material under the cows which will be hygenic and will decrease the risk of mastitis.


                  A Dairy Farm :

           Manure Scraper in the barn :

                                       

     
           Manure Separator on its Platform :

                                   

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